Coordinated modular building construction

ABSTRACT

A building composed of a number of modules. Each module has a depth extending from its front end to its back end, of: MD n X SD MD modular depth, N A WHOLE NUMBER &gt; OR = 2, SD segmental depth which is at least 2 feet, WHEREBY EACH MODULE COMPRISES AT LEAST TWO SEGMENTAL DEPTH UNITS. The modules are positioned so that parallel, vertical, coordinating planes of each module defined by the front end, back end, and each segmental depth unit thereof, are disposed in parallel planes spaced apart SD. Projections can be provided by having modules partially projecting beyond adjacent modules by an amount which is a whole number multiple of SD. Each module is provided with connecting means for securing the modules together and the connecting means are positioned so that the connecting means of the respective modules are coordinated for any selected assembly of the modules as aforesaid.

United States Patent [191 Fencl 1 Aug. 5, 1975 COORDINATED MODULAR BUILDING CONSTRUCTION 22 Filed: May 23, 1974 21 Appl. No: 472,925

Related US. Application Data [52] US. Cl. 52/79; 52/227; 52/234 [51] Int. Cl. E04H 9/06; EO4C 1/00 [58] Field of Search 52/79, 236, 234, 227

(56} References Cited UNlTED STATES PATENTS 3,564,795 2/1971 Henton 52/227 3,703,058 11/1972 Klett et 211.. 3,716,954 2/1973 3,750,366 8/1973 3,818,660 6/1974 Primary Examinerjames L, Ridgill, Jr. Attorney, Agent, or Firm-Burgess, Dinklage & Sprung [57] ABSTRACT A building composed of a number of modules. Each module has a depth extending from its front end to its back end, of:

MD n X SD M1) modular depth,

n a whole number 2,

SD segmental depth which is at least 2 feet, whereby each module comprises at least two segmental depth units. The modules are positioned so that parallel, vertical, coordinating planes of each module defined by the front end, back end, and each segmental depth unit thereof, are disposed in parallel planes spaced apart SD. Projections can be provided by having modules partially projecting beyond adjacent modules by an amount which is a whole number multiple of SD. Each module is provided with connecting means for securing the modules together and the connecting means are positioned so that the connecting means of the respective modules are coordinated for any selected assembly of the modules as aforesaid.

17 Claims, 2 Drawing Figures PATENTED AUB 5 975 SHEET W so 50 am I 3 8 FIGZ PATENTEB M15 5 SHEET PATENTEDAUG 5191:; 3.891662 saw FIG.8

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PATENTEU AUG 5|975 SHEET COORDINATED MODULAR BUILDING CONSTRUCTION CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of applica tion Ser. No. 369,562, filed on June 13, 1973, now abandoned, which is a continuationdn-part of an application Ser. No. 294,391, filed on Oct. 12, 1972, now abandoned, and which was a continuation-in-part of an application Ser. No. 289,935, filed on Sept. 18, 1972, now abandoned, and which was a continuation-in-part of application Ser. No. 143,547, filed on May 14,1971, now abandoned.

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of the modular building construction in which preformed building modules are manufactured under factory conditions and thus can be fully precompleted; they are assembled on the construction site to form a building in accordance with the predetermined architectural design. More particularly, this invention belongs in the group of construction techniques employing structurally selfsupporting modules, and it belongs to the class which may be characterized by the vertical stacking of modules with bearing-walls aligned. Finally, this invention belongs to the category of techniques in which modules can be assembled horizontally side-by-side, front end to back end, and/or vertically floor slab to ceiling slab. In some instances, side wall to back end assembly is used in this invention, According to a preferred embodiment, this invention further belongs to construction techniques using reinforced concrete as the predominant structural material.

Still further, this invention proposes the assembly of structural modules from structural components in an assemblyline process of manufacturing of building modules.

2. Description of the Prior Art Advantages of modular construction are generally well known and need not therefore be reasserted. As touched upon above, there are basically three types of modular techniques:

Group I employs selfsupporting modules;

Group II employs modules supported by a separate structural frame, either premanufactured Il-A, or cast in-situ IIB.

Group III employs modules supported by cast-in modular structure frame.

Group I may be classified with reference to the vertical arrangement of modules as follows:

Class A employs stacked modules with bearing-walls aligned;

Class B employs staggered modules with bearing walls aligned;

Class C employs stacked modules with bearingwalls alternately aligned.

With reference to the horizontal arrangement of modules, Group I may be further categorized as fol lows:

Category 1 employs modules of which each is part of the bay of the story;

Category 2 employs modules horizontally combined in a front end-to back end fashion;

Category 3 employs horizontally staggered modules;

Category 4 employs modules horizontally combined in an open end-to bearing side-wall fashion.

U.S. Pat. Nos. 3,712,007 and No. 3,527,002, as an example, belong to the Group II-A; U.S. Pat. No. 3,514,910 belongs to the Group III. In the opinion of this applicant, both Groups II and III are inferior to the Group 1 due to their inherent disadvantages which make them economically non-competitive, especially if they use metal as the predominant structural material.

U.S. Pat. Nos. 3,643,390 and No. 3,510,997 may be designated under I-B-I and 1-8-3. Both concepts are technologically inconsistent because they negate the very principle purpose of modular construction.

U.S. Pat. No. 3,716,954 is designated under LA and 8-1. This concept faces the problem of the inflexibility of the layout due to the rigidly predetermined allocation of certain facilities, and the problem of the uneconomical span due to the limited transportability of modules. Still further, different clear-heights another consequence of the concept will cause, at least partly, redundant structural height.

U.S. Pat. No. 3,703,058 is designated under I-A-4 and 2. It faces the problem of the inflexibility of the layout due to the rigidly predetermined relationship of horizontal modular dimensions and due to the roomsize" character of modules. Further, because of transportation limits, approximately 16 feet, the floor span is uneconomical.

It is the conclusion of the applicant, based on thorough analysis of all modular concepts, that this invention, which preferably comprises the construction of I-A-2 and 4 represents the most promising concent of all.

OBJECTS OF THE INVENTION A primary object of the present invention is to provide a novel method of the construction of buildings for dwelling, which, applying advanced manufacturing techniques available, should lead to the truly industrialized mass production of housing, thus drastically reducing the overall costs of dwelling.

In order to satisfy the immediate need for housing, a further object is to secure the immediate feasibility of the process of selecting materials and methods available without delay.

In order to further secure the immediate realization of the invention, another important object is to enable introduction into the market by starting with the application of a simple assembly line production on the site requiring very low, immediately amortizable investment and attain the ultimate goal full factory production in gradual stages.

In order to prevent an unnecessary delay in its implementation, a still further object is to propose a system adaptable to different building codes and zoning ordinances throughout the world.

In order to secure the economical result of the proposed process, a still further object is to keep the technology as simple as possible.

Simultaneously, however, a still further object is, that despite the inevitable introduction of the coordinating system, the invention should relinquish very little, possibly nothing of the flexibility of the architectural planning, exterior articulation and urbaniztic configuration.

A still further object is to provide a high quality ofliving, especially with respect to such criteria as sound insulation and fire safety.

A still further object is to secure the contributive character of the present invention in the field of ecology, namely to propose a system which should result in the construction of buildings with a pleasing esthetic appearance.

A still further object is to investigate all important aspects of the proposed process thoroughly in order to secure the technical feasibility and the economical competitiveness of the invention.

Embodiments of the invention are illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a schematic plan of the typical core circulation layout, employing the core building modules;

FIG. 2 is a schematic plan of the typical interior corridor circulation layout, employing the building modules with extended corridor slab;

FIG. 3 is a schematic plan of the typical interior corridor circulation layout, employing the corridor building modules;

FIG. 4 is a schematic isometric view of the modular cluster in accordance with FIG. I, showing separated upper and lower portions;

FIG. 5 is a schematic isometric view of the modular cluster in accordance with the part of FIG. 2, showing separated upper and lower portions;

FIG. 6 is a schematic isometric view of the modular cluster in accordance with the part of FIG. 3, showing separated upper and lower portions;

FIG. 7 is an enlarged detail of the encircled portion X of FIG. 4, showing the particular relationship of connecting means and coordinates;

FIG. 8 is an enlarged detail of the encircled portion Y of FIG. 5, showing the particular relationship of connecting means and coordinates;

FIG. 9 is an enlarged detail of the encircled portion Z of FIG. 6, showing the particular relationship of connecting means and coordinates;

FIG. 10 is a fragmentary vertical sectional view II indicated in FIG. 2, as related to the top portion of FIG.

FIG. 11 is a fragmentary vertical sectional view of Il indicated in FIG. 2, as related to the bottom portion of FIG. 5;

FIG. 12 is a fragmentary vertical sectional view II-II indicated in FIG. 3, as related to the top portion of FIG.

FIG. 13 is a fragmentary vertical sectional view IIlI indicated in FIG. 3, as related to the bottom portion of FIG. 6',

FIG. I4 is an enlarged fragmentary vertical sectional view cut perpendicularly to bearing'wall, illustrating the interconnection of four modular structures after the assembly of the modular cluster;

FIGS. l5, l6, 17 are examples of shapes of connecting plates;

FIG. I8 is a schematic, isometric, partially exploded view of the structure of a common building module 13 as is indicated in FIGS. 1 and 4',

FIG. 19 is a schematic, isometric, partially exploded view of the structure of a common building module in dicated in FIGS. 1 and 4;

FIG. 20 is an enlarged horizontal sectional view along lll-Ill indicated in FIG. 19;

FIG. 21 is a schematic, isometric, partially exploded view of the structure of the corridor building module with extended floor slab, indicated by 18 in FIG. 5;

FIG. 22 is a schematic, isometric, partially exploded view of the structure of the corridor wall building mod ule, indicated by 19 in FIG. 5;

FIG. 23 is a schematic, isometric, partially exploded view of the structure of the core building module 16 in FIGS. 1 and 5; and

FIG. 24 is a schematic, isometric, partially exploded view of the structure of the typical corridor building module 20 in FIGS. 3 and 6.

THE INVENTION The invention provides a building comprising an assembly of modules, each module being a hollow, rectangular body having a planar horizontal bottom closure, a planar horizontal top closure, front end and back end, and planar vertical sidewalls. Such a module is indicated by a reference character 34, in FIG. 4 and in FIG. 18 and FIG. 19. The modules are arranged to provide a plurality of contiguous bays, each bay being of uniform width, and a plurality of contiguous stories, each story being of uniform height, as is illustrated in FIG. 4. The bays include a first bay having at least two front to back horizontally aligned and substantially abutting modules. Those bays further comprise a sec ond bay, including at least one module disposed at the same level as the first bay, in overlapping relation with respect to the first bay. The said first and second bays form a first story of the building. At least one of said bays includes a module vertically stacked with respect to the module or modules of the first story with sidewalls of the stacked units in vertical alignment and the stacked units overlapping and contiguous. Thereby a second story of the building is provided.

Each module has a depth extending from its front end to its back end, which is:

MD n X SD wherein:

MD modular depth,

n a whole number 2,

SD segmental depth which is at least 2 feet.

Thus, said modules each include at least two segmental depth units of depth SD. Referring to FIG. 18, the modular depth is indicated by MD, and the segmental depths by SD. In the embodiment of FIG. 18, n is 3.

The modules are positioned so that the vertical paral lel planes of each module defined by the front end, back end, and each segmental depth unit thereof, are disposed in parallel, vertical, coordinating planes spaced apart SD.

The modules are assembled so that the building includes at least one module which projects outwardly in the direction of its modular depth beyond an adjacent module, eg a vertically adjacent module or a horizontally adjacent module. In FIG. 4, module 34 projects outwardly in the direction of its modular depth from the module there beneath. The amount of the projection is:

PD m X SD wherein:

PD projection depth,

m I a positive whole number less than the value of n for the projecting module,

SI) segmental depth.

Each module includes connecting means for securing of adjacent modules together. The connecting means of adjacent modules are in complementing relation for interconnection thereof to secure the module units together, and the disposition of the connecting means is such that there are complementing connecting means for any selected assembly of the modules as aforesaid. Connectors cooperate with the connecting means securing the modules together. Interconnection of modules is indicated by the showings in FIG. 4 and FIG. 14.

Thus, the projecting module always overlaps an adjacent module by an amount which is a whole number multiple of the segmental depth, and projections of different amounts can be selected, while at the same time there are complementing connecting means for connection to adjacent modules for each of the possible positions.

A feature of the invention is the provision of passageway openings in the sidewalls of two side-by-side, contiguous modules for passage between the two bays, the opening in each of the sidewalls being located within a segmental depth unit thereof.

Thus, referring to FIG. 18, the doorway openings 35 and 36 located within segmental depth units SD. That facilitates the design and construction of the building.

If, in the application of equations I and II to a building, there occurs more than one possible value for n and/or m, then the smaller value of n and/or m is/are taken.

Desirably, a module or modules of each bay have the same width which is equal to the width of the bay, and the module or modules of each story have the same height which is equal to the height of the story, and the width of each bay is the same and the height of each story is the same.

Also, in a preferred embodiment, the modules include modules of at least two different modular depths. In such an embodiment, the modular depths of each of the modules satisfies equation I.

Where there are modules of different modular depth, the segmental depth, SD, is to be the same for the various size modules.

In another preferred aspect of the invention, the segmental depth, SD, is at least 2 ft. 6 in., better 3 ft., and still better, 3 ft. 6 in. or 4 ft. As discussed above, it is desirable to include passageway openings such as openings for doors and windows within the segmental depth units. Accordingly, the segmental depth is advantageously of a size suitable for placement therein of such openings.

The modular depth, MD, is often determined by convenience of transportation of the modules. It can be up to 16 feet. If modules are assembled or produced on the job site, they can be any desired size.

Preferred values for n are 2 and 3.

Preferred values for m and l and 2.

Numerous variations in the building design are possi ble. Thus, a bay or bays can be disposed perpendicularly to the aforementioned bays, with the perpendicularly disposed bay composed of modules according to the invention. A perpendicularly disposed module can be disposed with its back end in substantially abutting relations with at least one of the planar vertical sidewalls of the adjacent bay of the assembly of modules, as is the case for module 37 shown in FIG. 4.

Desirably, at least one MW coordinate of the perpendicular module coincides with one of the SD coordinates of the adjacent assembly of modules. Thus, for the module 39 (FIG. 4), the modular width coordinates are 40 and 41, while the SD coordinates for the module 13 of the adjacent assembly of modules are 42, 43, 44, 45. As apparent from FIG. 4, the modular width coordinate 40 of perpendicularly disposed module 39 coincides with SD coordinate 42 of module 13. Typical interconnection of perpendicularly disposed modules is indicated by the showing in the circle marked X in FIG. 4, which showing is enlarged in FIG. 7.

Openings can be provided for vertical passage between stories. Thus, two modules, each as aforesaid, vertically stacked in aligned relationship can be provided with aligned, congruent openings, respectively, in the top closure of the lower module and the bottom closure of the upper module, so as to provide the passageway opening between the two stories. See FIG. 4, module 14, and FIG. 23.

The building can include corridors. Referring to FIGS. 3, 6, 12, 13 and 24, corridor modules 20 are hollow, completely rectangular bodies having planar horizontal bottom and top closures, and planar vertical front and back sidewalls, and end portions 38 (FIG. 24) which can be open end positions. Adjacent corridor modules are disposed with end portions thereof aligned and one in each bay, with the corridor module sidewalls substantially abutting with ends of the modules of the assembly. The confronting ends of the corridor modules are in communication for passage between the corridors.

Typical interconnection of corridor modules with common modules is shown in FIG. 6, in the circle marked Z, which showing is enlarged in FIG. 9.

Alternatively, the corridors can be provided as is indicated in FIGS. 2, 5, 10, 11, 21, 22. The corridor space is created in this case by corridor walls included in both modules located adjacent to the corridor (see FIGS, 10,11, 2], 22), and, further, by an transverse extension of the bottom slab of one of the mentioned modules, such as shown in FIG. 21. The space of the corridor of the top story is enclosed by a transversely extending ceiling slab of the complementing module as indicated in FIG. 10. The extension, as indicated in FIG. 21, is integral with the bottom closure.

Desirably, the corridor depth, CD is a whole number multiple of the segmental depth SD, and preferably is equal to 1 SD.

Where the construction indicated in FIG. 21, employing extensions for forming the corridors, is utilized, the modules with which the extensions are integral, desirably, have a modular depth as follows:

MD=p s0 wherein:

MD modular depth of module having an extension for the corridor,

p a positive whole number less than the value of n for the module of the building having the highest modular depth,

SD segmental depth.

As is apparent from FIG. 21, where a module has a corridor extension, the MD is the depth excluding the extension. The depth including the extension is the overall depth OD.

Observance of formula (III) will result in the modules having corridor extensions not exceeding, in overall depth, the MD of the module of greatest modular depth. That will facilitate transportation of modules.

(III) A typical interconnection of a module having an extended ceiling slab with an adjacent module providing a corridor wall, is shown in FIG. 8, which is an enlargement of the structure enclosed by circle Y in FIG. 5.

EMBODIMENTS The basic novelty of this invention is the typification and standardization of the entire construction process. In order to achieve it effectively, the construction pro cess is governed by a system of coordinated dimensions.

The coordinating system is the result of thorough studies, with the aim to accomplish the inevitable di mensional restrictions with the simultaneous preserva tion of the flexibility and variability of the architectural design.

The coordinating system regulates the construction process in the following manner:

1. It can estabish dimensional standards of all structural and modular components and of all nonstructural components and subassemblies.

2. It can decisively influence the selection of the method most suitable for the manufacture of structural components and modules.

3. It can determine the selection and the construction of all mechanisms and apparatus used in the construction process.

4. It can coordinate the positioning of the means for the structural interconnection of all building compnents.

For this reason, the successful use of this modular construction depends largely on a proper implementation of the coordinating system at all phases of the building process, especially at the phase of the design.

The coordinating system, characterized by the introduction of modular segments performing the role of a common denominator, is best described as follows. The typical body of the building, denoted as the modular cluster, is dissected into modular segments by a system of three types of coordinating planes:

The first type is horizontal planes which are geometrically determined either by the planes comprising the centers of the doubled floor structure 31 in FIG. 10, or by the top 32 in FIG. 10 or by the bottom 33 in FIG. 11 of the simple floor structure. Thus, described planes define the bottom, intermediate, and top stores (FIGS. 4, 5, and 6), establishing the particular height of the modular segments, which coincides with the height of the corresponding module, and is denoted generally as the modu lar height MII, specifically BMH, IMH, TMH. The various modular heights of the modules of a cluster are preferably the same.

The second type of coordinating planes are vertical planes geometrically determined either by centers of the doubled bearing wall structure 27 in FIG. I, or by the exterior surface of the simple bearing wall structure 28 in FIG. I. Such planes constitute the width of the bay, thus establishing the width of modular segments, which coincides with the width of the corresponding module and is therefore denoted as the modular width MW (FIGS. 1, 2, 3).

The third type of coordinating planes are vertical planes perpendicular to hearing walls, geometrically determined either by the front end or the back end of the modules, or by points dividing the distance between the front end and the back end of the modules into a multiplicity of units of equal depth. That unit is denoted as the segmental depth SD (FIGS. 1, 2, 3).

The above described rules of the coordinating system apply to buildings (FIGS. 1, 4) or portions of buildings (FIGS. 2, 3, S, 6) composed of modules characterized as common modules (FIGS. 18, 19), core modules (FIG. 23), or corridor wall modules (FIG. 4) all of which are rectangular prisms.

In the case of the what can be called interiorcorridor circulation layout employing modules with extended corridor slab 30 (FIGS. 5 and 21), SD planes simultaneously establish the corridor modular depth CMD, (FIGS. 2, 4), which can be a constituent of the particular bottom modular depth BMD (FIG. 21) or the top modular depth TMD (FIG. 10) of the modules with an extended corridor slab.

In the case of the interior-corridor circulation layout employing corridor modules 20 or 22 (FIGS. 3, 24), vertical coordinating planes simultaneously play a reverted role as MW becomes actually the depth of the corridor module, whereas CMD, eventually CMD SD (see module 22 in FIG. 3), becomes actually the width of the corridor module (FIG. 24).

Actual modular dimensions are not prescribed, as they are the result of many considerations, such as the weight and the transportability of building modules, economical aspects, design flexibility, etc.

The area of the modular segment becomes an established increment of which a multiplicity constitutes the apartment area and other areas, and therefore plays an important role in the architectural design. Assuming that the practically reasonable area increment should not be less than sq. ft., and that the economical MW is in the proximity of 25 feet, then SD should be at least 2 feet, preferably 2 ft. 6 in., or 3 ft. or 3 ft. 6 in. or 4 ft.

The significance of the coordinating system is greatly enhanced by its simultaneous role of coordinator of the positioning of connecting means needed to secure the modular construction together, and with the substructure, eventually with the superstructures.

In order to provide for the structural security of the building construction and simultaneously to allow for variation of the modular arrangement, providing projections and recessions of modules, in compliance with the coordinating system, the following rules can be observed:

]. The SD, preferably uniform throughout the building should be uniform at least within each group of parallel bays (FIG. 1).

2. The means for horizontal interconnection of the modular construction should be installed at least at such points of intersection of MW and SD grid lines, where a top corner of a module meets either another top corner of a horizontally adjacent module, or a SD grid line of a horizontally adjacent module.

3. The means for vertical interconnection of the modular construction should be installed at least at such points of intersection of the three coordinating planes, where any corner of a module meets either another corner of a vertically adjacent module, or a horizontal edge of a vertically adjacent module, substructure or superstructure.

4. The vertically interconnecting means should be positioned in modules on points:

a. at an uniform perpendicular distance D from SD grid lines, in the case of all modules except corridor modules (FIGS. 7-9 and 4, 6,10 I3, 15,18, 2

b. at an uniform perpendicular distance C from SD grid lines, in the case of corridor modules (FIGS. 13, 24);

c. and at an uniform perpendicular distance T from MW grid lines (FIGS. 4, 6-9 l4-l8, 20, 24).

It is preferable to locate all wall openings disposed along the width of a module, within SD to allow for the vertically continuous run of the connecting means throughout the height of the entire building structure. In such a case, SD is preferably at least about 3 ft. 6 in.

The proposed modular construction is applicable to many types of buildings for dwelling, especially for multi-family housing, hotels, dormitories, houses for elderly, etc. It is demonstrated here on 2 basic types of high-rise apartment houses the core circulation type (FIG. 1) and the interior corridor circulation type (FIGS. 2, 3).

The basic structural concept of the modular cluster is a cross bearing wall system. The lateral stability in the direction perpendicular to bearing walls can be secured partly by the rigidity of structural joints, and partly by shear walls applied within specific modules as core walls or corridor walls. In order to facilitate the architectural planning of the grade floor, a skeleton system is applied. Further, in order to speed up the erection of the grade floor, the structure is standardized.

The sequence of basic phases of the entire construction process (exclusive of foundation and subgrade structure) is as follows:

1. The premanufacture of standardized structural components of the typified grade floor (off-site, or on-site).

2. The premanufacture of standardized structural components of building modules (preferably offsite).

3. The assembly of the grade floor structure.

4. The manufacture of building modules (preferably off-site).

5. The assembly of the modular cluster.

6. The completion of the grade floor during the phase 7. The constructing of the roof superstructure.

l. The pre-manufacture of standardized structural concrete components of the typified grade floor. The grade floor structure may consist basically of:

a. Vertical frames illustrated in FIGS. 4, 5, 6 in their typical shapes.

b. Bracing girders 6, 8 positioned vertically or inclined (FIG. 4).

Both frames and girders are equipped with an embedded hardware for their structural interconnection. On the top of frames, connecting means 5 (FIG. 4) are positioned to receive the connecting means of the modular cluster. To accommodate service mechanical lines (e.g. electrical, water lines), openings 12 (FIG. 4) are provided in bracing girders.

2. The pre-manufacture of standarized structural concrete components of building modules. The size of these components is governed by the coordinating sys tem and further by the capacity of the manufacturing equipment, which also influences the shape of such components. There are the following typical modular components: common bearing wall, corridor bearing wall, core shear wall, corridor shear wall, common floor panel, common ceiling panel, core floor panel, core ceiling panel, corridor floor panel, corridor ceiling panel, cantilevered corridor floor panel, cantilevered corridor ceiling panel. Connecting means are provided in modular components. As an example of connecting means, apertures for connecting and reinforcing pipes 23 (FIGS. 10 14, I9, 20, 24) can be provided.

3. The assembly of the grade floor structure. An example of the assembled grade floor structure is illustrated in FIG. 4, showing the outline 15 of the perimeter of the modular cluster. Preferably, the interconnection of this structure is provided by a heavy hardware embedded in standardized components.

4. The manufacture of building modules. The structural enclosure of the building module is denoted as the structural module. There are following typical structural modules: common or simple (FIGS. l8, 19) which are rectangular prisms, core (FIG. 23), corridor wall (FIG. 22), corridor (FIG. 24), extended floor slab (FIG. 21), and extended ceiling slab module 26 (FIG. 10).

Structural modules are formed of structural components with the assistance of a mechanical apparatus denoted as an assembly jig-Compared with the monolithic pouring of boxes", this very important feature of this invention has the following significant advantages:

1. Structural components, being flat panels, can be manufactured by most advanced methods available, such as the method of hydraulic pressing which offers the accuracy of products at the level of mechanical engineering and reduces the production time to the fraction of the time needed by any other method.

2. The use of the assembly jig secures the highest possible accuracy of the assembly of structural modules, which is vitally important for the successful assembly of the modular cluster.

3. The use of fully cured components for the assembly of structural modules eliminates a serious problem of the creepage of the concrete (which occurs in the case of the monolithic pouring of boxes), and further contributes favorably to the provision of the desirable accuracy of the process.

4. The assembly jig is easily adaptable to any size and shape of structural modules, even to truncated shapes 7 illustrated as an example in FIG. 4.

5. The process of the assembly of structural modules in the assembly jig offers itself to automation.

6. In the assembly jig, the structural module may be composed of different kinds of concrete, such as of different densities or different strengths.

7. Structural modules can be manufactured from stock components, thus further speeding the entire construction process.

8. Because of the proposed process of assembly of structural modules requires short time (e.g. approximately 1 hour) it suitably fits into the assembly line process of the manufacture of building modules.

9. The use of the assembly jig makes it possible that in cases where structural components can be produced and delivered to the site for a feasible price, a simple assembly line production of modules can be performed on the site, thus reducing investment needed for the introduction of this construction method to the minimum.

Auxiliary superstructures, such as railing walls 2 (FIG. 4), or roof parapets 1 (FIG. 4) are installed preferably in the factory. If not permissable due to transportation difficulties, such components are installed on the site on the ground before lifting. Exterior infill closure 3 (FIG. 4) can be installed during the assembly line process.

5. The assembly of the modular cluster. The modular cluster is composed of building modules in accordance with the coordinating system characterized by coordinating planes described before. If we imagine the system of coordinating planes in form of a shelf register, then the role of the designer is to determine modular dimensions and fit modules, of which he chooses the optional depth, into the register as if inserting drawers. In cases, where modules project outwardly over vertically adjacent lower modules, for structural reasons, the projecting module should comprise at least 2 modular segments. Typically, such projections do not exceed SD," however larger projections are possible, depend ing on the actual dimension ofSD." Projected portion of modules may be truncated, in different shapes to enhance the esthetic effect, such as for example 7, illustrated in FIG. 4. Auxiliary structures, such as terraces 2a (FIG. 4), roof parapets 1 (FIGS. 4, 5), balconies 21 (FIG. 5), etc., are lifted into position together with the corresponding modules, whenever technically feasible. Modules with extended corridor slabs are assembled, both horizontally and vertically, either by projecting corridor slabs from the same side of the building, or in an alternated fashion.

Characteristic features of the modular cluster are stories and bays.

First, a horizontal combination of modules of two or more modules of identical MH" and MW," disposed in front to back relation is denoted as the modular row." Thus the building disclosed in FIG. 2 comprises five modular rows 29.

A story of the modular cluster then, is constituted by:

l. a single module,

2. or by a modular row,

3. or by an array of modules at the same horizontal level, comprising single modules disposed side-byside, or of modular rows, or of a combination of both single modules and modular rows.

A bay of the modular cluster then is constituted by:

l. a single module,

2. or by a modular row,

3. or by a vertical stack of modules, consisting of single modules, or of modular rows, or of a combination of both, modules and modular rows.

Following are the typical phases of the assembly of the modular cluster:

Step I Grout 46 (FIG. 14) is applied on the top of portions of the substructure and modules of the first story are installed stepwise. Projected connecting means 5 (FIG. 4) serve as guides facilitating the positioning of modules, lifting nuts 17 (FIG. 14) being used for the attachment of a lifting device (not shown).

Step 2 Vertical connecting means 9 (FIG. 14) are engaged in the corresponding means of the sub structure, and horizontal connecting means (FIGS. 4, 14) are mutually engaged. Vertical misalignment of modules can be prevented by installing washers on the top of connecting meansv Step 3 Electrical, signal, and other mechanical systems are interconnected in access openings in the top of the ceiling slabs.

Step 4 All structural joints are sealed and grout is applied on top of the story at suitable locations. Strips are applied at the perimeter to prevent the grount from oozing.

Step 5 Modules of the successive story are installed. Projecting connecting means 24 (FIG. 14) facilitate the installation.

Step 6 Vertical connecting means 9 and horizontal connecting means 4 are engaged and the process repeats from Step 2.

During the process, all mechanical lines inside the building are interconnected, all joints accessible from inside are sealed and surfaces of all structural and nonstructural joints are finished.

Separate auxiliary structures, such as balconies, etc. are attached to the modular cluster during the installation of the respective story.

6. The completion of the grade floor. As mentioned before, the grade floor is completed during the process of the assembly of the modular cluster.

7. The construction of the roof superstructures. Unless the roof parapet is delivered as part of the corresponding module and installed during the modular assembly, it is installed as a separate step.

Connecting means are provided then in top modules to attach any superstructures.

A complementing relation for connecting means of adjacent modules, according to the invention, can be seen in FIG. 4. If the modular units of the bay 47 are shifted in the direction of arrow 48 by one SD, connecting means of modules of bay 47, will be related to connecting means of hay 49, in the same way after the shifting as before the shiftingv The situation is the same if the modules of bay 49 are shifted by one SD in the direction indicated by arrow 50. Thus by the construction according to the invention, connecting means of the module which can be bores 51 are positioned for interconnection by connectors, such as plates 4 (FIG. 14), rods 9 and bolting 24, at any positioning of the modules according to the invention. Plates 4 of which typical shapes are shown in FIG. l5, l6, 17, of a given construction can be used for the various positions of the modules according to the invention.

While commonly, the modules are completely rectangular, such as the modules of FIGS. 5, 6, l8, 19, 22, 23 and 24, some of the modules can have a truncated portion, as is the case for module 7 of FIG. 4. The invention, however, contemplates that at least one segment defined by a SD, of each module, be completely rectangular. Preferably, only one of the outwardly disposed segments is modified in shape, the remaining segments being completely rectangular.

While the preferred embodiments have been described, it is to be comprehended, that various modifications of the present invention are possible without departing from the spirit of the invention. There will be instances where the typified grade floor structure may not apply, or will be used only partly, and cases, where some atypical structure, or atypical modules will be applied, or a combination of the modular system with cast in situ method, etc.

Consequently. it is to be understood that the present invention has been described by way of its demonstration and is therefore not limited to the way it has been presented.

What is claimed is:

1. A building comprising:

a. an assembly of modules, each module being a hollow. substantially rectangular body having a planar horizontal bottom closure, and a planar horizontal top closure, front end and back end, and planar vertical sidewalls,

b. said modules being arranged to provide a plurality of contiguous bays. each bay being of uniform width. and a plurality of contiguous stories, each story being of uniform height.

c. said bays comprising a first bay including at least two front to back horizontally aligned and substantially abutting modules, said bays further comprising a second bay including at least one module disposed at the same level as said two modules of the first bay, in overlapping relation with respect to the first bay, said two modules of the first bay and said one module of the second bay forming a first of said stories,

d. at least one of said bays including a module vertically stacked with respect to the module or modules of said first story with the side walls of the stacked units in vertical alignment and the stacked units overlapping and contiguous, forming a second of said stories,

e. each module having a depth, MD, extending from its front end to its back end which is:

MD n X SD wherein:

MD modular depth,

n a whole number g 2,

SD segmental depth which is at least 2 feet, whereby said modules each comprise at least two segmental depth units of depth SD,

f. the modules being positioned so that the parallel planes of each module defined by the front end, back end, and each segmental depth unit thereof, are disposed in parallel vertical, coordinating, planes spaced apart SD,

g. said modules being assembled so that the building includes at least one module which projects outwardly in the direction of its modular depth beyond an adjacent module by an amount which is:

PD m X SD wherein:

PD projection depth,

m a positive whole number less than the value of n for the projecting module,

SD segmental depth,

h. each module including connecting means for securing of adjacent modules together, the connecting means of adjacent modules being in complementing relation for inter-connection thereof, to secure the modules together, the disposition of the connecting means being such that there are complementing connecting means for any selected as sembly of the modules. as aforesaid, and

i connectors cooperating with said connecting means securing the modules together.

2. A building according to claim 1, wherein each bay is of substantially the same width and each story is of substantially the same height.

3. A building according to claim 1, wherein SD is at least 2 ft.-6 in.

4. A building according to claim 1, wherein SD is at least 3 ft.

5. A building according to claim 1, wherein SD is at least 3 ft.-6 in.

6. A building according to claim 1, wherein SD is at least 4 ft.

7. A building according to claim 1, and a bay disposed perpendicularly to said plurality of bays, including at least one module, as aforesaid, said one module being diposed with its back end in substantially abutting relations with at least one of the planar vertical sidewalls of the adjacent bay of said assembly of modules and with a modular width coordinate thereof aligned with a segmental depth coordinate of the module of said assembly with which the perpendicularly disposed module abuts, said one module being interconnected with the module which said one module abuts.

8. A building according to claim 1, and two cooridor modules which are hollow. completely rectangular bodies having a planar horizontal bottom and top closures, and planar vertical front and back side walls and end portions. the two corridor modules being interconnted with adjacent modules, and being disposed with end portions thereof aligned and one in each bay with the corridor module side walls substantially abutting with ends of adjacent modules of said assembly, the confronting ends of the corridor modules being in communication for passage between the corridors, the modular depth of said corridor modules being:

C MD r SD wherein:

CMD corridor modular depth,

r= is a positive whole number equal to or larger than SD said segmental depth.

9. A building according to claim 1, said assembly including additional modules, said additional modules being as aforesaid and disposed in said bays, said modules in the respective bays being in front to back horizontally aligned relation, a corridor extending trans versely across the bays having corridor sides, floor and ceiling, modules of each bay being disposed on each of the two sides of the corridor, the modules on each of said two sides being spaced to provide the corridor width, the corridor floor and ceiling being formed by extensions of bottom and top closures of modules next adjacent the corridor, said extensions being integral with the bottom and top closures from which they extend.

10. A building according to claim 9, the modules with which said extensions are integral being:

MD=p s0 wherein:

MD modular depth of module having an extension for the corridor,

p a positive whole number less than the value of n for the module of the building having highest modular depth,

SD segmental depth.

11. A building according to claim 1, and additional modules as aforesaid, and having a plurality of said projections.

12. A building according to claim 1, and passageway openings in the sidewalls of two side-by-side, contiguous modules for passage between the two bays, the

opening in each of the sidewalls being located within a segmental depth unit thereof.

13. A building according to claim 1, said modules ineluding modules of at least two different modular depths, the modular depths of each of said modules sat- 5 isfying said equation MD 11 SD.

14. A building according to claim 12, wherein SD is at least 2 ft.-6 in.

atleast4ft. 

1. A building comprising: a. an assembly of modules, each module being a hollow, substantially rectangular body having a planar horizontal bottom closure, and a planar horizontal top closure, front end and back end, and planar vertical sidewalls, b. said modules being arranged to provide a plurality of contiguous bays, each bay being of uniform width, and a plurality of contiguous stories, each story being of uniform height, c. said bays comprising a first bay including at least two front to back horizontally aligned and substantially abutting modules, said bays further comprising a second bay including at least one module disposed at the same level as said two modules of the first bay, in overlapping relation with respect to the first bay, said two modules of the first bay and said one module of the second bay forming a first of said stories, d. at least one of said bays including a module vertically stacked with respect to the module or modules of said first story with the side walls of the stacked units in vertical alignment and the stacked units overlapping and contiguous, forming a second of said stories, e. each module having a depth, MD, extending from its front end to its back end which is: MD n X SD wherein: MD modular depth, n a whole number < OR = 2, SD segmental depth which is at least 2 feet, whereby said modules each comprise at least two segmental depth units of depth SD, f. the modules being positioned so that the parallel planes of each module defined by the front end, back end, and each segmental depth unit thereof, are disposed in parallel vertical, coordinating, planes spaced apart SD, g. said modules being assembled so that the building includes at least one module which projects outwardly in the direction of its modular depth beyond an adjacent module by an amount which is: PD m X SD wherein: PD projection depth, m a positive whole number less than the value of n for the projecting module, SD segmental depth, h. each module including connecting means for securing of adjacent modules together, the connecting means of adjacent modules being in complementing relation for inter-connection thereof, to secure the modules together, the disposition of the connecting means being such that there are complementing connecting means for any selected assembly of the modules, as aforesaid, and i. connectors cooperating with said connecting means securing the modules together.
 2. A building according to claim 1, wherein each bay is of substantially the same width and each story is of substantially the same height.
 3. A building according to claim 1, wherein SD is at least 2 ft.-6 in.
 4. A building according to claim 1, wherein SD is aT least 3 ft.
 5. A building according to claim 1, wherein SD is at least 3 ft.-6 in.
 6. A building according to claim 1, wherein SD is at least 4 ft.
 7. A building according to claim 1, and a bay disposed perpendicularly to said plurality of bays, including at least one module, as aforesaid, said one module being diposed with its back end in substantially abutting relations with at least one of the planar vertical sidewalls of the adjacent bay of said assembly of modules and with a modular width coordinate thereof aligned with a segmental depth coordinate of the module of said assembly with which the perpendicularly disposed module abuts, said one module being interconnected with the module which said one module abuts.
 8. A building according to claim 1, and two cooridor modules which are hollow, completely rectangular bodies having a planar horizontal bottom and top closures, and planar vertical front and back side walls and end portions, the two corridor modules being interconnted with adjacent modules, and being disposed with end portions thereof aligned and one in each bay with the corridor module side walls substantially abutting with ends of adjacent modules of said assembly, the confronting ends of the corridor modules being in communication for passage between the corridors, the modular depth of said corridor modules being: CMD r SD wherein: CMD corridor modular depth, r is a positive whole number equal to or larger than 1, SD said segmental depth.
 9. A building according to claim 1, said assembly including additional modules, said additional modules being as aforesaid and disposed in said bays, said modules in the respective bays being in front to back horizontally aligned relation, a corridor extending transversely across the bays having corridor sides, floor and ceiling, modules of each bay being disposed on each of the two sides of the corridor, the modules on each of said two sides being spaced to provide the corridor width, the corridor floor and ceiling being formed by extensions of bottom and top closures of modules next adjacent the corridor, said extensions being integral with the bottom and top closures from which they extend.
 10. A building according to claim 9, the modules with which said extensions are integral being: MD p X SD wherein: MD modular depth of module having an extension for the corridor, p a positive whole number less than the value of n for the module of the building having highest modular depth, SD segmental depth.
 11. A building according to claim 1, and additional modules as aforesaid, and having a plurality of said projections.
 12. A building according to claim 1, and passageway openings in the sidewalls of two side-by-side, contiguous modules for passage between the two bays, the opening in each of the sidewalls being located within a segmental depth unit thereof.
 13. A building according to claim 1, said modules including modules of at least two different modular depths, the modular depths of each of said modules satisfying said equation MD n SD.
 14. A building according to claim 12, wherein SD is at least 2 ft.-6 in.
 15. A building according to claim 12, wherein SD is at least 3 ft.
 16. A building according to claim 12, wherein SD is at least 3 ft.-6 in.
 17. A building according to claim 12, wherein SD is at least 4 ft. 